Replace complete rear fender · ar6350p1400y · Mercedes-Benz WIS

AR63.50-P-1400Y

Replace complete rear fender

18.11.11

MODEL 219

P63.50-3076-06

1 Rear fender

	Removing
 Danger!	Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes.	Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system.	AS00.00-Z-0007-01A
 Danger!	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
 Danger!	Risk of injury caused by scraping or cutting body parts on sharp vehicle parts	Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels.	AS00.00-Z-0017-01A
 Danger!	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Measures for preventing damage to vehicles or components when performing electric welding work	All models	AH00.00-N-0005-01A
	General information on body repair	All models	AH60.00-N-0001-01A
	Notes on paintwork repairs	Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 199, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639	AH98.00-P-9408-02A
	General information on MB materials	Model 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 414, 463, 639	AH98.00-P-9409-03A
1	Remove rear door sill molding		AR68.30-P-4100TX
2	Remove rear wall window		AR67.20-P-2000Y
3	Remove taillamps		AR82.10-P-4905TX
4	Remove rear bumper		AR88.20-P-2200TX
5	Remove detachable parts in trunk, in area of rear fender
6.1	Install filler neck covering	When replacing right rear fender with deeper damage.	AR63.50-P-1400-01Y
		 Set of covers	*211589009100
7	Cover all detachable parts remaining in vehicle	Tarp (fire-resistant)
8	Separate rear fender (1)		AR63.50-P-1400-02Y
	Sheet metal crimping pliers for areas not easily accessible		WF58.50-P-6350-01Y
		 Spot weld milling cutter	*201589005100
		 Set of cutting templates	*219589012300
		Ball cutter, dia. 12 mm
		Vario Drill WS 91 spot weld removing tool
		Beading pliers
		Round wire brush, braided, dia. 70 mm
		Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
		Hot air gun - 3000 W
		Drill gotis://K_58.1_04.0
		Body jig saw gotis://K_58.1_01.0
		Wet/dry vacuum cleaner gotis://P_00.12_06.0
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
9	Prepare new rear fender (1)		AR63.50-P-1400-03Y
		 Set of cutting templates	*219589012300
		Round wire brush, braided, dia. 70 mm
		Drill gotis://K_58.1_04.0
		Body jig saw gotis://K_58.1_01.0
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
	Install
10	Install rear fender (1) and weld in		AR63.50-P-1400-04Y
	General information on riveting	Model 168, 169, 171, 199, 203, 209, 211, 215, 219, 230, 240, 414, 639, 903	AH60.00-P-0003-01N
		Rear door to side piece, bottom	*BE60.00-P-1002-01O
		Trunk lid to rear fender, top	*BE60.00-P-1003-01O
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01O
		Rear fender to lamp unit	*BE60.00-P-1003-01O
		Fuel filler flap	*BE60.00-P-1004-01O
		 Feeler gauge	*129589032100
		 Bending iron	*129589002700
		Electrode miller
		Clamping pliers
		Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver
		Round wire brush, braided, dia. 70 mm
	Taurus 3 blind rivet tool with 100 mm extension unit	Blind rivet/punch riveting method gotis://K_68-80_06.0
		MIG MAG gas welder (steel, brazing, aluminum) gotis://K_60-65_17.1
		Inverter spot welder gotis://K_60-65_16.0
		Drill gotis://K_58.1_04.0
		Wet/dry vacuum cleaner gotis://P_00.12_06.0
		Zinc dust paint suitable for spot welding	*BR00.45-Z-1001-07A
		Polygrip flat round head rivet, 6.414	*BR00.45-Z-1001-13A
		Sealant	*BR00.45-Z-1003-01A
11	Adjust gap dimensions on hoods, doors and lids		AR60.00-P-0700-01Y
		Feeler gauge	*129589032100
		Rear door to side piece, bottom	*BE60.00-P-1002-01O
		Trunk lid to rear fender, top	*BE60.00-P-1003-01O
		Trunk lid to rear lamp unit	*BE60.00-P-1003-01O
		Rear fender to lamp unit	*BE60.00-P-1003-01O
		Fuel filler flap	*BE60.00-P-1004-01O
12	Remove covers for filler neck	When replacing right rear fender with deeper damage.	AR63.50-P-1400-01Y
		 Set of covers	*211589009100
13	Clean weld joints and sheet metal flange with round wire brush	Round wire brush, braided, dia. 70 mm
		Drill gotis://K_58.1_04.0
14	Clean repair areas
15	Prime repair area using primer filler
16	Carry out seam sealing after repairs	 Supplement standard sealants with MB body sealant.	AR97.10-P-4000Y
		Sealant	*BR00.45-Z-1003-01A
		Seam sealant, sprayable 310 ml	*BR00.45-Z-1041-01A
17	Paint repair areas and adjacent surfaces
18	Apply additional cavity preservation		AR97.20-P-1500Y
	Notes on cavity preservation	Model 124, 126, 129, 140, 168, 169, 170, 171, 201, 202, 203, 208, 209, 210, 211, 215, 219, 220, 230, 240, 463, 639, 671, 690.6, 901, 902, 903, 904, 905 Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7	AH97.20-P-0001-01B
		Combination pressure spray gun (corrosion protection) gotis://K_91-97_01.0
		MB cavity wax preservation, 1 l	*BR00.45-Z-1003-05A
19	Remove tarp	 On all covered parts remaining in vehicle.
20	Install detachable parts in luggage compartment, in area of rear fender
21	Install rear wall window		AR67.20-P-2000Y
22	Install taillamps		AR82.10-P-4905TX
23	Install rear bumper		AR88.20-P-2200TX
24	Install rear door sill molding		AR68.30-P-4100TX

Test values for gap dimensions on hoods, doors and lids

Number	Designation				Model 219


BE60.00-P-1002-01O	Gap dimension	Fender to A-pillar	Dim. "D"	mm	3.0 (1)
		Front door to fender	Dim. "E"	mm	4.0 (-0.5/+1)
		Front door to rear door	Dim. "F"	mm	5.0 (-1/+0.5)
		B-pillar cover to front window	Dim. "G"	mm	10 (1)
		B-pillar cover to rear window	Dim. "H"	mm	10 (1)
		Rear door to side piece, bottom	Dim. "I"	mm	3.5 (-0.5/+1)
			See picture		AR60.00-P-0700-01Y
BE60.00-P-1003-01O	Gap dimension	Trunk lid to rear fender, top	Dim. "J"	mm	4.0 (0.5)
		Trunk lid to rear lamp unit	Dim. "K"	mm	2.5 (0.5)
		Trunk lid to bumper	Dim. "L"	mm	7.0 (1)
		Rear fender to lamp unit	Dim. "M"	mm	2.5 (0.5)
			See picture		AR60.00-P-0700-01Y
BE60.00-P-1004-01O	Gap dimension	Fuel filler flap	Dim. "N"	mm	3.5 (0.5)
			See picture		AR60.00-P-0700-01Y

219 589 01 23 00

Feeler gauge

Set of cutting templates

Spot weld milling cutter

Bending iron

201 589 00 51 00

129 589 03 21 00

129 589 00 27 00

Set of covers

211 589 00 91 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1003-01A	White sealing compound, 310 ml, DBL 6069.20	A 001 989 63 20
BR00.45-Z-1041-01A	Seam sealant, sprayable 310 ml	A 002 989 84 20
BR00.45-Z-1003-05A	Cavity sealant, solvent-free (1 l container)	A 000 986 72 70 05
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42
BR00.45-Z-1001-13A	Blind rivet 6.414	A 003 990 35 97

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